Particulate catch basin for condensate drain line

ABSTRACT

A particulate catch basin device for a condensate drain line used with an air conditioning system is described. The device includes a detachable water container in which solid particulates are captured. The detachable water container is connected to a head apparatus to which a condensate water line is attached. Water inside the detachable water container operates as a trap to capture particulates contained in condensate water entering into the device from an air handler through the condensate water line. Water, with the particulates removed by their capture within the detachable water container, flows out of the device through a connected drain pipe. A maximum water height within the detachable water container and head should not exceed a point that is lower than a lowest point of entry into the drain pipe. The device can include transparent materials to facilitate monitoring of the accumulation of particulates within the detachable water container.

FIELD OF THE INVENTION

The invention relates to air conditioner systems. More particularly, the invention relates to a particulate catch basin for a condensate drain line of an air conditioner system.

BACKGROUND

Conventional air conditioner systems (also called an air conditioner, an air conditioning system, and a HVAC) include a trap pipe to prevent air from moving into or out of the system during operation through the condensate line. Trap pipes (also called traps) are prone to clogging as particulates in the condensate water exiting the air handler collect within the trap pipe. Once the trap pipe becomes clogged, the system ceases to operate and does not cool the air. Condensate water can also back up within the system and flow out of the air handler damaging walls, flooring, or other items.

A need exists for a device that captures and collects particulates contained in condensate water exiting an air handler so that an air conditioner system's drain line does not become clogged. Another need exists for a device that captures and collects particulates contained in condensate water exiting an air handler, wherein the device is easily cleanable and the captured particulates easily removed. Still another need exists for a device that captures and collects particulates contained in condensate water exiting an air handler, wherein the captured particulates are visible within the device so that it may be cleaned before it becomes filled with particulates.

SUMMARY

The invention relates to a particulate catch basin device for a condensate drain line used with an air conditioning system is described. The device includes a detachable water container in which solid particulates are captured. The detachable water container is connected to a head apparatus to which a condensate water line is attached. Water inside the detachable water container operates as a trap to capture particulates contained in condensate water entering into the device from an air handler through the condensate water line. Water, with the particulates removed by their capture within the detachable water container, flows out of the device through a connected drain pipe. A maximum water height within the detachable water container and head should not exceed a point that is lower than a lowest point of entry into the drain pipe. The device can include transparent materials to facilitate monitoring of the accumulation of particulates within the detachable water container.

The particulate catch basin device provides an advantage over conventional air conditioning systems by capturing and collecting particulates contained in condensate water exiting an air handler so that an air conditioner system's drain line does not become clogged. The particulate catch basin device also provides an advantage over conventional air conditioning systems by capturing and collecting particulates contained in condensate water exiting an air handler in a way that the device is easily cleanable and the captured particulates easily removed. The particulate catch basin device provides another advantage by capturing and collecting particulates contained in condensate water exiting an air handler so that the captured particulates are visible within the device, thereby allowing it to be cleaned before it becomes filled with particulates.

Accordingly, the invention features a particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system. The device includes a head apparatus, a container in which particulates are captured from a condensate, a condensate line connecting an air handler to the head apparatus at the top aperture, and a drain line connected to the side aperture for allowing condensate water to exit the container. The head apparatus includes a top portion, a bottom portion, and a side wall. The top portion includes a top side and a bottom side. A top aperture extends through the head apparatus from its top side to its bottom side. A side aperture extends from an outer surface of the side wall through the side wall into an interior space of the head apparatus. A top open portion of the container is detachably connectable to the bottom portion of the head apparatus. Condensate water from the air handler flows through the condensate line and into the head apparatus and particulates are trapped therein.

In another aspect, the invention can feature the head apparatus being constructed from a transparent material.

In another aspect, the invention can feature the container being constructed from a transparent material.

In another aspect, the invention can feature the condensate line, the drain line, or both being constructed from a transparent material.

In another aspect, the invention can feature the container including an overflow trough attached to an outer surface of the container to catch condensate water when the container is detached from the head apparatus.

In another aspect, the invention can feature the container being cylindrical in shape and the overflow trough being annular in shape.

In another aspect, the invention can feature condensate water from the air handler entering the container through the head apparatus from the condensate line and collecting within the container so that a maximum water level within the container is near a lower inner surface of the drain pipe so that excess condensate water flows out of the drain pipe.

In another aspect, the invention can feature the bottom portion of the head apparatus including threading and a top portion of the container also including threading so that the container is attachable to the bottom portion of the head apparatus by screwing the top portion of the container over or into the bottom portion of the head apparatus.

In another aspect, the invention can feature the condensate line being part of an existing air conditioner system and the head apparatus being installable so as to be connected to the existing air conditioner system.

The invention also features a particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system. The device includes a head apparatus, a container in which particulates are captured from a condensate, a condensate line connecting an air handler to the head apparatus at the top aperture, and a drain line connected to the side aperture for allowing condensate water to exit the container. The head apparatus includes a top portion, a bottom portion, and a side wall. The top portion includes a top side and a bottom side. A top aperture extends through the head apparatus from its top side to its bottom side. A side aperture extends from an outer surface of the side wall through the side wall into an interior space of the head apparatus. A top open portion of the container is detachably connectable to the bottom portion of the head apparatus. Condensate water from the air handler flows through the condensate line and into the head apparatus and particulates are trapped therein. The head apparatus, the container, or both are constructed from a transparent material.

In another aspect, the invention can feature the container including an overflow trough attached to an outer surface of the container to catch condensate water when the container is detached from the head apparatus.

In another aspect, the invention can feature the container being cylindrical in shape and the overflow trough being annular in shape.

In another aspect, the invention can feature condensate water from the air handler entering the container through the head apparatus from the condensate line and collecting within the container so that a maximum water level within the container is near a lower inner surface of the drain pipe so that excess condensate water flows out of the drain pipe.

In another aspect, the invention can feature the bottom portion of the head apparatus including threading and a top portion of the container also including threading so that the container is attachable to the bottom portion of the head apparatus by screwing the top portion of the container over or into the bottom portion of the head apparatus.

A method of the invention can be used for capturing and removing particulates in a flow of condensate water from an air handler of an air conditioner system. The method includes the steps of: (a) connecting a particulate catch basin device to a condensate line attached to an air handler, wherein the particulate catch basin device includes: (i) a head apparatus having a top portion, a bottom portion, and a side wall; wherein the top portion includes a top side and a bottom side; wherein a top aperture extends through the head apparatus from its top side to its bottom side; wherein a side aperture extends from an outer surface of the side wall through the side wall into an interior space of the head apparatus; wherein the condensate line is connected to the head apparatus at the top aperture, and wherein condensate water from the air handler flows through the condensate line and into the head apparatus; (ii) a container in which particulates are captured from a condensate, wherein a top open portion of the container is detachably connectable to the bottom portion of the head apparatus; and (iii) a drain line connected to the side aperture. The method also includes the steps of (b) capturing particulates in condensate water flowing from the air handler through the condensate line within the container of the particulate catch basin device; and (c) allowing condensate water with particulates removed to flow out of the particulate catch basin device through the drain pipe.

Another method of the invention includes the steps of: (d) detaching the container from the head apparatus and emptying the container of particulates captured within the container from the condensate water; and (e) reattaching the container to the head apparatus.

Another method of the invention includes the container being constructed from a transparent material so that the amount of particulates collected within a bottom of the container is visible without detaching the container from the head apparatus.

Another method of the invention includes the head apparatus being constructed from a transparent material so that the amount of particulates collected within a bottom of the container is visible through the head apparatus without detaching the container from the head apparatus.

Another method of the invention includes step (d) of the method further including the step of: (f) when the container is detached from the head apparatus, catching condensate water that may spill from the container in an overflow trough attached to an outer surface of the container.

Another method of the invention includes the condensate line being part of an existing air conditioner system and the head apparatus being installable so as to be connected to the existing air conditioner system.

Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. In the case of conflict, the present specification, including definitions will control.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a particulate catch basin for a condensate drain line.

FIG. 2 is a front view of a head of the particulate catch basin of FIG. 1.

FIG. 3 is a top plan view of the head of FIG. 2.

FIG. 4 is a bottom plan view of the head of FIG. 2.

FIG. 5 is a front view of the container of the particulate catch basin of FIG. 1.

FIG. 6 is a top perspective view of the container of FIG. 5.

DETAILED DESCRIPTION

The present invention is best understood by reference to the detailed drawings and description set forth herein. Embodiments of the invention are discussed below with reference to the drawings; however, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. For example, in light of the teachings of the present invention, those skilled in the art will recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein beyond the particular implementation choices in the following embodiments described and shown. That is, numerous modifications and variations of the invention may exist that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive.

The present invention should not be limited to the particular methodology, compounds, materials, manufacturing techniques, uses, and applications, described herein, as these may vary. The terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. Similarly, for another example, a reference to “a step” or “a means” may be a reference to one or more steps or means and may include sub-steps and subservient means.

All conjunctions used herein are to be understood in the most inclusive sense possible. Thus, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should be read as “and/or” unless expressly stated otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.

Unless otherwise defined, all terms (including technical and scientific terms) are to be given their ordinary and customary meaning to a person of ordinary skill in the art, and are not to be limited to a special or customized meaning unless expressly so defined herein.

Terms and phrases used in this application, and variations thereof, especially in the appended claims, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing, the term “including” should be read to mean “including, without limitation,” “including but not limited to,” or the like; the term “having” should be interpreted as “having at least”; the term “includes” should be interpreted as “includes but is not limited to”; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; and use of terms like “preferably,” “preferred,” “desired,” “desirable,” or “exemplary” and words of similar meaning should not be understood as implying that certain features are critical, essential, or even important to the structure or function of the invention, but instead as merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the invention.

Those skilled in the art will also understand that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations; however, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C” is used, in general, such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.).

All numbers expressing dimensions, quantities of ingredients, reaction conditions, and so forth used in the specification are to be understood as being modified in all instances by the term “about” unless expressly stated otherwise. Accordingly, unless indicated to the contrary, the numerical parameters set forth herein are approximations that may vary depending upon the desired properties sought to be obtained.

The invention provides a particulate catch basin device 10 for capturing particulates flowing through a condensate drain line of an air conditioner system. The device 10 can be incorporated as a part of a new air conditioner system or can be installed in communication with a drain line of an existing air conditioner system. The device 10 includes a head apparatus 12 having a top portion 12 a, a bottom portion 12 b, and a side wall 12 c. The top portion 12 a of the head apparatus 12 includes a top side 22 and a bottom side 24. A top aperture 26 extends through the head apparatus 12 from its top side 22 to its bottom side 24. A side aperture 28 extends from an outer surface 30 of the side wall 12 c through an inner surface 32 of the side wall into an interior space 34 of the head apparatus 12. The device 10 also includes a container 14 in which particulates are captured from a condensate, i.e., condensate water. A top portion 14 a of the container 14 is detachably connectable to the bottom portion 12 b of the head apparatus 12. The top portion 14 a of the container 14 includes an opening 14 d that communicates with the interior space 34 of the head apparatus 12. The device 10 further includes a condensate line 16 connecting an air handler to the head apparatus 12 at the top aperture 26. The condensate line 16 and air handler can be part of a new air conditioning system of which the device 10 is a component, or alternatively, they can be part of an existing air conditioning system in which the device 10 is installed to retrofit the existing air conditioning system thereby improving its operation. The device 10 also includes a drain line 18 connected to the side aperture 28 for allowing condensate water to exit the container 14. Condensate water from the air handler flows through the condensate line 16 and into the head apparatus 12 and particulates are trapped in the container 14 that is attached to the head apparatus.

In one embodiment, the head apparatus 12 can be constructed from a transparent material. In another embodiment, the container 14 can be constructed from a transparent material. In another embodiment, one or both of the condensate line 16 and the drain line 18 can be constructed from a transparent material. In exemplary embodiments, the head apparatus 12, container 14, and drain line 18 may all be constructed from transparent materials. The transparency of the material used to construct these parts of the device 10 allows for viewing of a level of accumulated particulates within the container 14 and for clogging of the drain line 16. In still another embodiment, the condensate line 18 can be constructed from a transparent material.

In one exemplary embodiment, the container 14 includes an overflow trough 20 attached to an outer surface 14 b of the container to catch condensate water when the container is detached from the head apparatus 12. For example, if the container 14 is nearly filled with condensate water and particulates, the water level within an interior space 14 c of the container will be high and water may spill out of the container during its separation from the head apparatus 12. In exemplary embodiments, the container 14 is cylindrical in shape and the overflow trough 20 is annular in shape. In other embodiments, the container 14 and overflow trough 20 may have other non-circular shapes.

Condensate water from the air handler enters the container through the head apparatus 12 from the condensate line 16 that exits the air handler. The condensate water collects within the container 14 so that a maximum water level within the container is near a lower inner surface 18 a of the drain pipe 18 so that excess condensate water flows out of the drain pipe. Once water within the container 14 rises to the level of the lower inner surface 18 a of the drain pipe 18, the water flows into and through the drain pipe to exit the air conditioner system.

In exemplary embodiments, the bottom portion 12 b of the head apparatus 12 includes threading and the top portion 14 a of the container 14 also includes threading so that the container is attachable to the bottom portion 12 b of the head apparatus by screwing the top portion of the container over or into the bottom portion of the head apparatus. In other embodiments, the container 14 may be attached to the head apparatus 12 by other means such as clamps, snaps, latches, or similar connection apparatuses.

The condensate line 16 can be part of an existing air conditioner system and the head apparatus 12 is installable so as to be connected to the existing air conditioner system at the connection of the condensate line to the head apparatus.

The invention also includes a method for capturing and removing particulates in a flow of condensate water from an air handler of an air conditioner system. The method uses the particulate catch basin devices described herein above. In one step of the method, a particulate catch basin device is connected to a condensate line attached to an air handler. In the next step of the method, particulates in condensate water flowing from the air handler through the condensate line are captured within the container of the particulate catch basin device. In the next step of the method, condensate water with particulates removed is allowed to flow out of the particulate catch basin device through the drain pipe.

In another step of the method, the container is removed from the head apparatus and the container is emptied and cleaned of particulates captured within the container from the condensate water. In a related step, when the container is detached from the head apparatus, condensate water that may spill from the container is captured in an overflow trough attached to an outer surface of the container. The container is reattached to the head apparatus after removal and cleaning.

In another step of method, the amount of particulates collected within a bottom of the container is determined without detaching the container from the head apparatus by viewing the particulate level through the container wall, wherein the container is constructed from a transparent material. In another embodiment of this step, the head apparatus may be constructed from a transparent material so that the particulate level within the container may be determined visibly by looking through the head apparatus.

In an alternative step of the method, the condensate line can be part of an existing air conditioner system and the head apparatus is installable so as to be connected to the existing air conditioner system to enable retrofitting of old air conditioner systems to improve performance by preventing clogging of drain lines.

OTHER EMBODIMENTS

It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims. 

1: A particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system, the device comprising: a head apparatus comprising a top portion, a bottom portion, and a side wall; wherein the top portion comprises a top side and a bottom side; wherein a top aperture extends through the head apparatus from its top side to its bottom side; and wherein a side aperture extends from an outer surface of the side wall through the side wall into an interior space of the head apparatus; a container in which particulates are captured from a condensate, wherein a top open portion of the container is detachably connectable to the bottom portion of the head apparatus; wherein once detached from the head apparatus, the container is emptiable to cleanly remove particulates from the condensate, which have been captured inside the container; a condensate line connecting an air handler to the head apparatus at the top aperture, wherein condensate water from the air handler flows through the condensate line and into the head apparatus; and a drain line connected to the side aperture for allowing condensate water to exit the container. 2: The particulate catch basin device of claim 1, wherein the head apparatus is constructed from a transparent material. 3: The particulate catch basin device of claim 1, wherein the container is constructed from a transparent material. 4: The particulate catch basin device of claim 1, wherein the condensate line, the drain line, or both are constructed from a transparent material. 5: The particulate catch basin device of claim 1, wherein the container comprises an overflow trough attached to an outer surface of the container to catch condensate water when the container is detached from the head apparatus. 6: The particulate catch basin device of claim 5, wherein the container is cylindrical in shape and the overflow trough is annular in shape. 7: The particulate catch basin device of claim 1, wherein condensate water from the air handler enters the container through the head apparatus from the condensate line and collects within the container so that a maximum water level within the container is near a lower inner surface of the drain pipe so that excess condensate water flows out of the drain pipe. 8: The particulate catch basin device of claim 1, wherein the bottom portion of the head apparatus comprises threading and a top portion of the container also comprises threading so that the container is attachable to the bottom portion of the head apparatus by screwing the top portion of the container over or into the bottom portion of the head apparatus. 9: The particulate catch basin device of claim 1, wherein the condensate line is part of an existing air conditioner system and the head apparatus is installable so as to be connected to the existing air conditioner system. 10: A particulate catch basin device for capturing particulates flowing through a condensate drain line of an air conditioner system, the device comprising: a head apparatus comprising a top portion, a bottom portion, and a side wall; wherein the top portion comprises a top side and a bottom side; wherein a top aperture extends through the head apparatus from its top side to its bottom side; and wherein a side aperture extends from an outer surface of the side wall through the side wall into an interior space of the head apparatus; a container in which particulates are captured from a condensate, wherein a top open portion of the container is detachably connectable to the bottom portion of the head apparatus; wherein once detached from the head apparatus, the container is emptiable to cleanly remove particulates from the condensate, which have been captured inside the container; a condensate line connecting an air handler to the head apparatus at the top aperture, wherein condensate water from the air handler flows through the condensate line and into the head apparatus; and a drain line connected to the side aperture for allowing condensate water to exit the container; wherein the head apparatus, the container, or both are constructed from a transparent material. 11: The particulate catch basin device of claim 9, wherein the container comprises an overflow trough attached to an outer surface of the container to catch condensate water when the container is detached from the head apparatus. 12: The particulate catch basin device of claim 10, wherein the container is cylindrical in shape and the overflow trough is annular in shape. 13: The particulate catch basin device of claim 9, wherein condensate water from the air handler enters container through the head apparatus from the condensate line and collects within the container so that a maximum water level within the container is near a lower inner surface of the drain pipe so that excess condensate water flows out of the drain pipe. 14: The particulate catch basin device of claim 9, wherein the bottom portion of the head apparatus comprises threading and a top portion of the container also comprises threading so that the container is attachable to the bottom portion of the head apparatus by screwing the top portion of the container over or into the bottom portion of the head apparatus. 15: A method for capturing and removing particulates in a flow of condensate water from an air handler of an air conditioner system, the method comprising the steps of: (a) connecting a particulate catch basin device to a condensate line attached to an air handler, wherein the particulate catch basin device comprises: a head apparatus comprising a top portion, a bottom portion, and a side wall; wherein the top portion comprises a top side and a bottom side; wherein a top aperture extends through the head apparatus from its top side to its bottom side; wherein a side aperture extends from an outer surface of the side wall through the side wall into an interior space of the head apparatus; wherein the condensate line is connected to the head apparatus at the top aperture; and wherein condensate water from the air handler flows through the condensate line and into the head apparatus; a container in which particulates are captured from a condensate, wherein a top open portion of the container is detachably connectable to the bottom portion of the head apparatus; wherein once detached from the head apparatus, the container is emptiable to cleanly remove particulates from the condensate, which have been captured inside the container; and a drain line connected to the side aperture; (b) capturing particulates in condensate water flowing from the air handler through the condensate line within the container of the particulate catch basin device; and (c) allowing condensate water with particulates removed to flow out of the particulate catch basin device through the drain pipe. 16: The method of claim 14, further comprising the steps of: (d) detaching the container from the head apparatus and emptying the container of particulates captured within the container from the condensate water; and (e) reattaching the container to the head apparatus. 17: The method of claim 14, wherein the container is constructed from a transparent material so that the amount of particulates collected within a bottom of the container is visible without detaching the container from the head apparatus. 18: The method of claim 14, wherein the head apparatus is constructed from a transparent material so that the amount of particulates collected within a bottom of the container is visible through the head apparatus without detaching the container from the head apparatus. 19: The method of claim 14, wherein step (d) of the method further comprises the step of: (f) when the container is detached from the head apparatus, catching condensate water that may spill from the container in an overflow trough attached to an outer surface of the container. 20: The method of claim 14, wherein the condensate line is part of an existing air conditioner system and the head apparatus is installable so as to be connected to the existing air conditioner system. 